1. International Journal of Research in Advent Technology, Vol.2, No.5, May 2014
E-ISSN: 2321-9637
Analysis of Effect of Different Process Parameters on the
Properties of the Component Manufacture Using FDM
63
Machine
Pawan V Mulkarwar1, Abhijit D. Munishwar2, Prof. Ashish M Wankhade3, Prof. Mansur N Syed4
Department –Mechanical Engineering1,2,3,4
Affliation Name-Student of Jawaharlal Darda Institute Of Engineering &Technology ,Yavatmal1
Affliation Name-Student of Jawaharlal Darda Institute Of Engineering &Technology ,Yavatmal2
Affliation Name-Asst.Prof Of Jawaharlal Darda Institute Of Engineering &Technology ,Yavatmal3
Affliation Name-Asst.Prof Of Jawaharlal Darda Institute Of Engineering &Technology ,Yavatmal4
Email Address -mulkarwarpawan4@gmail.com1
Abstract- The rapid prototyping is an emerging technology in developing the physical prototypes from the 3D cad
models by using the additive process with layers. FDM is one such RP technique which can build parts using layer
by layer deposition technique using thermoplastic building material according to numerically defined cross sectional
geometry. The quality of FDM produced parts is significantly affected by various parameters like build orientation,
road width, air gap etc. This dissertation work aims to study the effect of three process parameters such as Road
width, Air gap and sample orientation on properties. To achieve this the sample machine part were manufactured at
different orientation (0o,45o,90o) at min, med, max road width and air gap. Specimens is further analyzed for
accuracy, surface finish and build time. Results are tabulated and are shown graphically representation.
Index Terms-Minimum, Medium, Maximum
1. INTRODUCTION:
Measures to improve the efficiency of production
processes always include the application of new and
innovative manufacturing methods. Therefore, in recent
years, applications of the rapid technology turned out to
be potentials of the modern product development
process [1].compared with traditional material removing
method, rp technology is an additive material method
based on layer manufacturing (lm) technique. Rp’s
additive nature allows it to create objects with
complicated internal features that cannot be
manufactured by other means. In all commercial rp
processes, the part is fabricated by deposition of layers
contoured in a (x-y) plane two dimensionally. The third
dimension (z) results from single layers being stacked
up on top of each other, but not as a continuous z-coordinate.
Therefore, the prototypes are very exact on
the x-y plane but have stair-stepping effect in z-direction.
In recent decades, rp technologies have been
widely developed and used in different applications, and
even being applied as a direct manufacturing route to
applications in automobile and aerospace [2].
Since1986, more than ten main technics of rpm
technology were developed such as stereolithography
(SL), laminated object manufacturing (LOM),selective
laser sin-tering (SLS), selective laser melting (SLM),
fused deposition modeling (FDM), ink jet printing (IJP),
3-d printing (3DP), patternless casting
manufacturing(PCM), and electron beam selective
melting (EBSM). Of course, rapid prototyping is not
perfect. Part volume is generally limited to 0.125 cubic
meters or less, depending on the rp machine. Metal
prototypes are difficult to make, though this should
change in the near future. For metal parts, large
production runs, or simple objects, conventional
manufacturing techniques are usually more economical.
These limitations aside, rapid prototyping is a
remarkable technology that is revolutionizing the
manufacturing process. This paper includes the
manufacturing of specimen i.e connecting rod model at
three different build orientations i.e.at three different
angles (0o,45o,90o) along with different road width and

2. International Journal of Research in Advent Technology, Vol.2, No.5, May 2014
E-ISSN: 2321-9637
64
air gap(Min, Med, Max) separately by the rapid
prototyping technique(FDM).Then we will get the
readings of different parameters like build time, support
material required, model material required for above
orientation. Also we will test the above prototypes for
surface roughness, accuracy and tabulate the readings.
After analyzing the readings we will conclude the effect
of process parameters on properties of model and will
compromises at better orientation.
2. LITERATURE REVIEW:-
Alexander et al. developed an accuracy
calculation model and the methodology for creating the
cost model. Cusp height is used to measure the accuracy
of a part. The part orientation that minimizes part
accuracy, build time and the amount of support material
selected. The accuracy is calculated using the cusp
height that considers the area of each part in the stereo
lithography. The best orientation is chosen in terms of
the user from the results calculated.
The ability to select the optimal
orientation of buildup is one of the critical factors since
it affects the part surface quality, accuracy, build time
and part cost. Various factors to be considered in
optimization of build orientation for FDM are build
material, support material; build up time, surface
roughness and total cost. Experiments were carried out
and results are analyses for varying build orientation for
primitive geometries like cylinder. A mathematical
model was developed after validating the theoretical
values of surface roughness with measured values. This
helps in reducing experimental work and improves
possibilities of virtual simulation of rapid prototyping
parts (chenget. al.1995)
This paper presents a generic system that
performs a computer-aided optimization of part
orientation in consideration of the mentioned factors of
influence as well as related effects. The proprietary
development of the implementation of the presented
approach is based on the paradigm of object-oriented
and generic programming and therefore versatile. A
vertical orientation would result in good part quality
except the holes but also in a high number of layers and
therefore in longbuild time. A horizontal orientation
would lead to a cost-effective build time but also to
insufficient dimensional accuracy.(S. Danjou 1, P.
Koehler et. al.2009).
Paper represent characterize some of the
properties of Stratasys. Fused Deposition Modeling
(FDM) process, as well as the effects of varying some
of the build parameters. Series of Samples were
manufactured at FDM m/c and tested for load using
inston load frame. In the tension tests, the predicted
behavior does not correlate very well with the measured
behavior when the correct material properties are used.
However, when the tensile strength in the transverse
direction with a negative airgap is substituted into the
no airgap material properties, the predictive model is
quite accurate (John Michael Brock et. al.2000).
2.1 FDM:- FDM is one of the RP technology developed
by Stratasys, USA. But unlike other RP systems which
involve an array of lasers, powders, resins, this process
uses heated thermoplastic filaments which are extruded
from the tip of nozzle in a temperature controlled
environment. For this there is a material deposition
subsystem known as head (Figure 3.2) which consist of
two liquefier tips. One tip for model material and other
tip for support material deposition both of which works
alternatively. The article forming material is supplied to
the head in the form of a flexible strand of solid material
from a supply source (reel). One pair of pulleys or
rollers having a nip in between are utilized as material
advance mechanism to grip a flexible strand of
modeling material and advance it into a heated
dispensing or liquefier head. The material is heated
above its solidification temperature by a heater on the
dispensing head and extruded in a semi molten state on
a previously deposited material onto the build platform
following the designed tool path. The head is attached to
the carriage that moves along the X-Y plane. The build
platform moves along the Z direction. The drive motion
are provided to selectively move the build platform and
dispensing head relative to each other in a
predetermined pattern through drive signals input to the
drive motors from CAD/CAM system. The fabricated
part takes the form of a laminate composite with
vertically stacked layers, each of which consists of
contiguous material fibres or rasters with interstitial
voids. Fibre-to-fibre bonding within and between layers

3. International Journal of Research in Advent Technology, Vol.2, No.5, May 2014
E-ISSN: 2321-9637
65
occurs by a thermally-driven diffusion bonding process
during solidification of the semi-liquid extruded fibre.
2.2 Advantages:-
(1)Quick and cheap generation of models
(2)There is no worry of exposure to toxic chemicals,
lasers or a liquid chemical bath.
2.3Disadvantages:-
(1)Restricted accuracy due to the shape of material
used, wire is 1.27 mm diameter.
Fig. 1:- FDM Process
3. MATERIAL:- ABS is an ideal material for
conceptual modeling, functional prototyping and direct
digital manufacturing. Acrylonitrile - Butadiene -
Styrene (ABS) identifies a family of engineering
thermoplastics with a broad range of performance
characteristics. The copolymeric system is alloyed to
yield the optimum balance of properties suited to the
selected end use.
3.1 ACRYLONITRILE - Imparts chemical resistance
and rigidity.
3.2 BUTADIENE - Endows the product with impact
strength, toughness and abrasion resistance.
3.3 STYRENE – Contributes to the lustre, ease of
processing and rigidity.
The outstanding properties of ABS are:
1.High impact ,strength and ductility, which combine to
give exceptional toughness.
2. Good chemical resistance.
3. Abrasion resistance.
4 High strength solvent weld jointing which allows
efficient system assembly and modification.
5. Rubber Ring joint methods, allowing compatible
systems jointing techniques.
6. Nontoxic and non-taint properties.
7. Withstands aggressive ground waters.
8. High strain tolerance for buried applications.
9. Good resistance to ultraviolet light.
10. Lower celerity and extreme tolerance to water
hammer.

4. International Journal of Research in Advent Technology, Vol.2, No.5, May 2014
E-ISSN: 2321-9637
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Fig 2: General view connecting rod
4. METHODOLOGY:- The methodology of the
project is described in following steps:-
4.1 Selection of specimen:- We selected the simple
m/c part i.e connecting rod of two stroke engine as
specimen.
4.2 Design of specimen:-After selecting the specimen,
we measured out the actual dimensions of specimen.
Optimized Connecting Rod has been modeled with the
help of CATIA, in general we had perform the reverse
engg. The Orthographic and Solid Model of optimized
connecting rod is shown below.
4.3 FABRICATION OF MODEL:- Actual fabricated
prototypes of specimen at different build orientation i.e
0o,45o,90 along with different process parameters i.e
roadwidth and air gap Min(00,450,900), Med(00,450,900),
Max(00,450,900) on FDM TITAN T1 machine. ABS was
used as Raw material for fabrication of model. We
fabricated nine models i.e for each angle,
Min(00,450,900),Med(00,450,900),Max(00,450,900) road
width and air gap was varied.
5. OBSERVATION AND ANALYSIS:- Fabricated
model at 00,450,900 with Min,Med,Max, roadwidth
and airgap and the reading for orientation at an
interval of 450each an taken from system software.
Fabricated models were tested for surface roughness
at parth metallurgical services. Instrument named
SRT(Times-TR 110) was used for same. Accuracy of
models was determined with the help of digital
vernier calliper. Readings are tabulated as below,

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Table 1:- Surface Roughness Values of Connecting rod
Table 1:- Surface Roughness Values of Connecting rod
Sample
no. Location
Ra Values(um)
Top Bottom
R1 R2 R3 Avg R1 R2 R3 Avg
Min
45o
Dia 40 mm 13.69 14.76 14.47 14.31 15.28 14.9 14.52 14.90
Dia 18 mm 13.7 13.39 14.44 13.84 13.98 14.14 13.56 13.86
Rib 15.04 15.31 15.22 15.19 14.78 15.03 15.14 14.98
Med
45o
Dia 40 mm 15.26 15.4 14.92 15.19 14.92 15.16 14.77 14.95
Dia 18 mm 15.06 14.68 15.06 14.93 14.86 14.88 15.08 14.94
Rib 15.69 15.35 15.9 15.65 15.18 14.98 15.39 15.18
Max
45o
Dia 40 mm 14.44 13.83 14.03 14.10 14.2 14.57 14 14.26
Dia 18 mm 14.43 13.83 13.59 13.95 13.9 14.34 13.88 14.04
Rib 14.74 14.47 14.66 14.62 14.88 14.63 14.52 14.68
Max
0o
Dia 40 mm 13.76 14.22 14.02 14 14.2 14.32 13.84 14.12
Dia 18 mm 14.17 14.18 13.48 13.94 14.04 13.46 13.92 13.81
Rib 15 14.46 14.66 14.71 14.72 15.16 15.06 14.98
Max
90o
Dia 40 mm 14.12 14.52 13.84 14.16 14.29 13.96 13.32 13.86
Dia 18 mm 14.05 14 14.5 14.18 14.48 13.55 14.27 14.10
Rib 14.78 15.09 14.96 14.94 14.52 14.7 14.62 14.61

6. International Journal of Research in Advent Technology, Vol.2, No.5, May 2014
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Table 2:- Dimension of prototypes for accuracy
Sr.no Build
Type
Wt.
(gm)
Dia 40 mm Dia 80 mm Dia
40mm
Dia
18mm
Rim Notches
Inner Outter Inner Outter
1 Max
0o
15 29.73 39.90 14.81 18.03 15.27 15.25 9.42 3.68
2 Max
45o
16 29.60 39.77 14.77 17.90 15.25 15.24 9.35 3.74
3 Max
90o
18 29.81 39.90 14.83 17.88 15.43 15.33 9.54 3.62
4 Med
0o
18 29.78 39.92 14.84 18.06 15.30 15.30 9.43 3.50
5 Med
45o
20 29.88 39.83 14.81 17.94 15.50 15.28 9.38 3.56
6 Med
90o
15 29.90 39.94 14.95 17.92 15.45 15.34 9.57 3.36
7 Min
0o
19 29.95 39.94 14.90 18.11 15.48 15.33 9.60 3.14
8 Min
45o
19 29.96 39.03 14.98 18.05 15.69 15.35 9.45 3.23
9 Min
90o
10 29.93 39.97 15.08 18.03 15.51 15.42 9.59 3.27

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Table 3:- Material and time required for different orientation
Sr. no. Build type Time req.(min) Material req.
Maximum
1. Max00 1.22 1.06
2. Max150 1.17 1.06
3. Max300 1.18 1.07
4. Max450 1.18 1.07
5. Max600 1.12 1.06
6. Max900 1.11 1.06
Medium
1. Med00 1.12 1.27
2. Med150 1.09 1.27
3. Med300 1.11 1.27
4. Med450 1.09 1.29
5. Med600 1.08 1.28
6. Med900 1.08 1.27
Minimum
1. Min00 1.39 1.29
2. Min150 1.31 1.29
3. Min300 1.29 1.25
4. Min450 1.30 1.29

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5 Min600 1.32 1.29
6. Min900 1.21 1.29
6. RESULT AND CONCLUSION:-
This Paper represent an approach
that determines optimal build orientation for FDM,
Also the effect of process parameters like Road
width, Air gap, build material, support material on
the properties of component i.e Accuracy, Surface
roughness and build time. The minimization of Build
material and support material is also implicitly
included in work. The values of build time, Accuracy
and surface roughness are determined for varying
Road width and Air gap,
Min(00,450,900),Med(00,450,900),Max(00,450,900) at
each angle. From the computed Values of Build time,
Model material, Accuracy, Surface roughness,
Support material Required, its effect on build
orientation and optimal orientation is determined.
For the Specimen taken i.e
Connecting rod which is manufactured at varying
raod width and air gap along with Different angles, It
is found that for minimum road width and air gap
build time and model material taken is more,
followed by maximum and medium once. Also from
the surface roughness values it is observed that

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surface finish of maximum road width and air gap
prototypes is excellent and it decreases with increases
in angles (00,450,900). Form the accuracy point of
view better accuracy is obtained at minimum road
width and air gap.
REFERENCE:-
[1] Part orientation and build cost determination in
layered manufacturing’, P. Alexander, S. Allen,
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[2] Multi objective optimization of build orientation
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Anjikar, A. Venu Gopal, Department of
Mechanical Engineering, National Institute of
Technology, Warangal, Research Scholar, Dept.
Of Mechanical Engineering, NIT–Warangal,
INDIA.
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[5] Fused deposition modeling material properties
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[8]‘Investigation of The Effect of Various Build
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(1996), Journal of Materials Processing
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[9]Part orientation and build cost determination in
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